JPWO2020090063A1 - Production support system - Google Patents

Abstract

A production support system (10) that generates a process for producing a product based on an order including information for specifying a product to be produced, a quantity or quantity to be produced, and a due date for completing the production. , An input unit (34) for inputting an order, a plurality of work machines required to produce a product specified by an order based on an order input from the input unit, a process undertaken by each work machine, and the like. A schedule calculation unit (12) that generates a schedule including information on the time required to execute each process, and a plurality of tasks that are information that can be executed by each work machine interpreting each process of the generated schedule. It includes a process disassembly information providing unit (18) for disassembling and a process commanding unit (14) for outputting a command to each work machine based on a task from the process disassembling information providing unit.

Description

The present invention relates to a production support system suitable for high-mix low-volume production or high-mix variable production.

In the manufacturing industry, in addition to various standard products, various options are prepared in order to meet various needs, and high-mix low-volume production or high-mix variable production is performed by a manufacturing method called mass customization. Trying to fit into production. As an example of a production system for such high-mix low-volume production or high-mix variable-volume production, Patent Document 1 describes, in a high-mix variable-volume production line having a plurality of manufacturing processes, a process flow that matches the actual state of the line. Describes a system that accurately creates the standard and accurately changes the process flow for each product type.

Japanese Unexamined Patent Publication No. 09-260235

These days, market needs are constantly changing, and they are changing very quickly. Therefore, in order to meet such changing needs, it is difficult to construct a production system suitable for high-mix low-volume production or high-mix variable production that maintains high productivity.

The present invention has a technical problem of solving such a conventional problem, and provides a production system capable of easily generating a highly productive process in a production system in which various processing machines are mixed and processed. The purpose is.

In order to achieve the above object, according to the present invention, the product is made based on an order including information for identifying a product to be produced, a quantity or quantity to be produced, and a due date for completion of production. In a production support system that generates a process for production, an input unit for inputting an order and a plurality of work machines required to produce a product specified by the order based on the order input from the input unit. , A schedule calculation unit that generates a schedule including information on the processes that each work machine is in charge of and the time required to execute each process, and information that each work machine can interpret and execute each process of the generated schedule. A production support system including a process decomposition information providing unit that decomposes into at least one task and a process command unit that outputs a command to each work machine based on the task from the process decomposition information providing unit is provided. ..

Based on the order including the product name, product number or model number, quantity or quantity, and delivery date, which is abstract for the production system and cannot be executed as it is, a schedule that more concretely describes the contents of the order is generated. Based on the schedule, each process is decomposed into a plurality of tasks which are information that can be interpreted and executed by each work machine, and commands are output to each work machine based on the tasks. If the schedule calculation unit creates a schedule so that a specific process does not significantly control the production volume or become a bottleneck in the production process, it is possible to improve the production efficiency of the entire production system. Further, according to the present embodiment, even if a plurality of products are mixed in one production system, the work machines constituting the production system can be efficiently operated. It is possible to construct a production system suitable for variable-mix production.

It is a block diagram which shows the production support system by the preferable embodiment of this invention. It is a block diagram which shows the process plan or the basic process which is stored in the process plan database in association with the product name, the product number or the model number of the product to be manufactured. It is a figure which shows an example of the schedule generated by the schedule calculation unit. It is a figure which shows the work transfer process included in a schedule by the process of a further subordinate concept. It is a figure which shows the example which divided the roughing process by a cutting process into a more specific process. It is a figure which shows the example which divided the work attachment | removal process into a more specific process. It is a figure which shows the example which divided the roughing process into more concrete tasks which can be interpreted and executed at a machine level. It is a figure which shows the example which divided the finishing process by electric discharge machining into more specific process. It is a figure which shows the example which divided the process for finish machining by electric discharge machining into more concrete tasks which can be interpreted and executed at a machine level. It is a figure which shows the process by dividing it hierarchically. It is a figure which shows the information related to the task stored in the process decomposition information database. It is a figure which shows an example of a series of tasks output from a process decomposition information providing part to a process command part. It is a figure which shows another example of a series of tasks output from a process decomposition information providing part to a process command part. It is a block diagram which shows an example of the production system to which this invention is applied.

Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings.
First, referring to FIG. 14, the production system 100 is illustrated as an example of a production system to which the present invention can be applied. In this example, the production system 100 has three machine tools 110, 120, and 130 as at least one machine tool. The production system 100 further comprises a production support system 10, a workstation 150, a tool station 160, and between the machine tools 110, 120, 130 and the workstation 150 and the tool station 160, which are connected to the machine tools 110, 120, 130. The unmanned transport trolley 140 for transporting the work W, the tool T, or the electrode E is provided.

In the present invention, the machine tools 110, 120, 130, and the automatic guided vehicle 140 of the production system 100 are referred to as work machines that execute the process. FIG. 14 shows three machine tools 110, 120, 130 and two automatic guided vehicles 140, but this is merely an example, and the present invention describes the types of work machines illustrated. Not limited to the number.

The workstation 150 can include a feed workstation 152 that holds the raw work and a discharge workstation 154 that holds the processed work. The tool station 160 can hold spare tools and unused electrodes.

The machine tool 100 is an electric discharge machine, and has an electric discharge machine main body 112 and an electrode changing device 114 in which a plurality of electrodes are stored. The electrode changing device 114 replaces the stored electrode with the electrode E mounted on the tip of the main shaft (not shown) of the electric discharge machine main body 112 at any time. The electric discharge machine main body 112 includes a processing tank 116 provided so as to be movable relative to the electrode E of the main shaft. The electric discharge machine main body 112, the electrode changing device 114, and the machining tank 116 are housed in the cover 110a. The electric discharge machine 110 also includes a control device C1 such as an NC device that controls an electric discharge machine main body 112, an electrode changing device 114, and a processing tank 116. The electric discharge machine 110 discharge-machines the work W immersed in the processing liquid filled in the processing tank 116 by the electrode E. The electric discharge machine main body 112 can be a pore electric discharge machine, a die-sinking electric discharge machine, or a wire electric discharge machine.

In FIG. 14, the machine tool 120, which is the first machine tool, is a vertical machining center and has a cutting machine 122 such as a vertical milling machine and a tool changer 124 that stores a plurality of tools. .. The processing machine 122 and the tool changing device 124 are housed in the cover 120a. The machine tool 120 also includes a control device C2 such as an NC device. The tool changing device 124 selects a tool to be used for machining from a plurality of stored tools according to a machining program input to the control device C2, and replaces the tool T mounted on the spindle 122b of the machining machine 122 at any time. The machine tool 120 relatively moves the tool T mounted on the spindle 122b and the work W attached to the table 122a, and cuts the work W by the tool T.

In FIG. 14, the second machine tool, the machine tool 130, is a horizontal machining center, and includes a cutting machine 132 such as a horizontal milling machine, a tool changing device 134 for storing a plurality of tools, and a work changing device 138. Have. The processing machine 132 and the tool changing device 134 are housed in the cover 130a. The cover 130a is provided with a door 130b that opens and closes between the processing chamber where processing is performed and the internal space of the work changing device 138. The machine tool 130 also includes a control device C3 such as an NC device. The tool changing device 134 selects a tool to be used for machining from a plurality of stored tools according to a machining program input to the control device C3, and replaces the tool T mounted on the spindle 132b of the machining machine 132 at any time. In the machine tool 130, the work W is attached to the table 132a via the Iker 136a. The machine tool 130 relatively moves the tool T mounted on the spindle 132b and the work W attached to the table 132a, and cuts the work W by the tool T.

In the work changing device 138, the raw work W'stands by while being attached to the ikele 136b, and the raw work W'is referred to as the processed work W when the currently ongoing machining process is completed. Will be exchanged. The processed work W is transported to the outside by an automatic guided vehicle 140, for example, to a discharge workstation 154 that temporarily holds the processed work W by opening the door 138a provided on the side surface of the cover of the work changing device 138. Will be done.

The automatic guided vehicle 140 is an automatic guided vehicle that is connected to the production support system 10 by wireless communication such as a wireless LAN and is controlled by the production support system 10, and is an articulated robot arm 142. And an end effector 144 such as a robot hand attached to the tip of the robot arm 142. The end effector 144 grips or holds the work W or the pallet to which the work W is attached (not shown), the tool T and the tool holder to which the tool T is attached, and the electrode E and the electrode holder to which the electrode E is attached (not shown). It is possible to do.

Referring to FIG. 1, the production support system 10 includes a schedule calculation unit 12, a process command unit 14, an estimated work time providing unit 16, a process decomposition information providing unit 18, a process planning database 20, a working time database 22, and a process decomposition information database. 24 and a plurality of machine control units 26 and 28 are provided as main components, and these components include a microprocessor such as a CPU (central processing unit), a RAM (random access memory), and a ROM ( One or more computer devices including memory devices such as read-only memory), storage devices such as HDDs (hard disk drives) and SSDs (solid state drives), input / output ports, and bidirectional buses that interconnect them. It can consist of and related software. The production support system 10 is connected to the control devices C1, C2, and C3 of the machine machines 110, 120, and 130 of the production system 100, outputs commands to the control devices C1, C2, and C3, and outputs commands to the control devices C1, C2, and C2. , Receive data from C3.

An order is input to the schedule calculation unit 12 through the input unit 34. The order may include information identifying the product to be produced, such as product name, product number or model number, information on the quantity or quantity to be produced, and information on the due date or delivery date to complete production. can. The order may include information about options that are changes from standard products. The order can be entered by the user who operates the production system 100 or the operator of the production system 100. When the user or operator of the production system 100 inputs, the input unit 34 can be a computer device (personal computer or tablet) connected to the production support system 10 via a network such as a LAN. The order may also be entered by the orderer or customer of the product. In that case, the input unit 34 can be a computer device (personal computer or tablet) of the orderer or the customer connected via the Internet. Alternatively, the input unit 34 can be a server of 100 users of the production system connected to the computer of the ordering party or the customer via the Internet.

The schedule calculation unit 12 refers to the process planning database 20 based on the order input from the input unit 34, and outputs the schedule to the process command unit 14. The process plan database 20 stores a process plan or a basic process in association with a product name, a product number, or a model number of a product to be manufactured, as shown in FIG. FIG. 2 shows, as an example, a step 26 of manufacturing a die A by high-precision die machining, which is a work transfer step 38 of transporting a work W to a machine tool 120 or 130 for machining by an unmanned transfer machine 140. Roughing process 40 by cutting in machine 120 or 130, work transfer process 42 in which work W is transferred from machine tool 120 or 130 for electric discharge machining to machine tool 110 for electric discharge machining by unmanned transfer trolley 140, for electric discharge machining. It is shown that the machine tool 120 includes a finishing processing process 44 by electric discharge machining and a work transfer process 46 in which the work W is transferred from the machine tool 120 for electric discharge machining to the workstation 154 for electric discharge by the unmanned transfer machine 140. There is.

The schedule calculation unit 12 outputs the process plan (FIG. 2) obtained by referring to the process plan database 20 to the estimated work time providing unit 16. The estimated work time providing unit 16 refers to the work time database 22 to obtain the time required for each process 38 to 46. In the working time database 22, each of the working machines 110 to 140 of the production system 100 (working machines MC1, MC2, MC3, ED1, ED2, UC1, UC2 in FIG. 3 described later) are associated with steps 38 to 46. Estimated time to execute is preset and stored.

The schedule calculation unit 12 totals the time required for each process 38 to 46 output from the estimated work time providing unit 16, and produces a product according to the order input from the input unit 34 as shown in FIG. The schedule for manufacturing is output to the process command unit 14. In FIG. 3, MC1, MC2, MC3, ED1, ED2, UC1, and UC2 are work machines, and the horizontal axis is required for each work machine MC1, MC2, MC3, ED1, ED2, UC1, and UC2 to execute the process. It's time.

In FIG. 14, as a production system to which the present invention can be applied, a production system 100 including two machine tools 120 and 130 for cutting and one machine tool 110 for electric discharge machining has been described. In FIG. 3, the schedule includes three machine tools MC1, MC2, MC3 for cutting, two machine tools ED1 and ED2 for electric discharge machining, and at least two unmanned transport trolleys UC1 and UC2. It is a schedule for the production system.

FIG. 3 shows a case where two orders # 10 and # 11 are input to the schedule calculation unit 12. In FIG. 3, the two orders # 10 and # 11 shown as an example are both manufactured with high precision requiring rough machining 46 by cutting and finish machining 44 by electric discharge machining as shown in FIG. It is an order for a mold that has been made. In FIG. 3, SC1 to SC5 show each step for manufacturing the mold according to order # 10, and SC6 to SC10 show each step for manufacturing the mold according to order # 11. Steps SC1 to SC5 and SC6 to SC10 in FIG. 3 correspond to the steps 38 to 46 in FIG.

More specifically, in FIG. 3, in order to manufacture a die according to order # 10, an unmanned work is transported by an unmanned transport trolley UC1 to a machine tool MC3 for cutting (SC1), and the unprocessed work is machined. Roughing is performed by cutting in the machine MC3 (SC2), the roughened work is conveyed to the machine tool ED1 for electric discharge machining by the unmanned transport trolley UC1 (SC3), and the roughened work is electric discharge machined in the machine tool ED1. (SC4), and the machine tool that has been finished is transported to the electric discharge workstation by the unmanned transport trolley UC1 (SC5). From FIG. 3, it can be understood that for order # 10, all processes are completed around 17:30 pm.

Similarly, in order to manufacture the die according to order # 11, the unprocessed work is transferred to the machine tool MC2 for machining by the unmanned transport trolley UC2 (SC6), and the unprocessed work is machine tool MC2 by machining. Roughing (SC7), the roughened work is conveyed to the machine tool ED2 for electric discharge machining by the unmanned transport trolley UC2 (SC8), and the roughened work is finished by electric discharge machining on the machine tool ED2 (SC9). ), The finished work is transported to the electric discharge workstation by the unmanned transport trolley UC2 (SC10). From FIG. 3, it can be understood that for order # 11, all processes are completed around 18:30 pm.

In this way, the schedule calculation unit 12 allows the currently available work machines MC1, MC2, MC3, ED1, ED2, UC1, UC2, and each work machine to execute each process SC1 to SC5 and SC6 to SC10. Considering the time required, a schedule is created for all orders # 10 and # 11 so that the products can be manufactured within the delivery date.

As will be described later, the process command unit 14 outputs the schedule received from the schedule calculation unit 12 to the process decomposition information providing unit 18. The process decomposition information providing unit 18 refers to the process decomposition information database 24 based on the processes SC1 to SC5 and SC6 to SC10 described in the received schedule, and each process SC1 to SC5 described in the schedule. And SC6 to SC10 are further decomposed.

For example, the work transfer steps 38 (steps SC1 and SC6 in FIG. 3), 42 (steps SC3 and SC8 in FIG. 3) and 46 (steps SC5 and SC10 in FIG. 3) of FIG. 2 are as shown in FIG. Includes one step 38', 42', 46' that cannot be further decomposed.

On the other hand, in the roughing process 40 by the cutting process of FIG. 2 (processes SC2 and SC7 in FIG. 3), as shown in FIG. 5, the raw work W is put on the table 122a or 132a of the machine tool 120 or 130, for example. It can be disassembled into a work attaching step 48 to be fixed, a processing step 50, and a step 52 to remove from the table 122a or 132a.

With reference to FIG. 6, in the work mounting step 48 (step 64 in the case of discharge machining described later) or the work removing step 52 (step 68 in the case of discharge machining described later), the robot arm 142 of the unmanned transport trolley 140 is fed. Step 52 of moving the work toward one work on the workstation 152, step 54 of gripping the work by the end effector 144, moving the robot arm 142 toward the table 122a of the machine tool 120 or the work changing device 138 of the machine tool 130. It can be disassembled into the moving step 56. In the work removal process, the process is the reverse of the reverse order, but it can also be disassembled into three processes.

The machining step 50 of FIG. 5 can be further decomposed into one or more more specific steps that execute individual machining programs. In FIG. 7, the machining step 50 is decomposed into three steps 58, 60, 62 that execute the machining programs O0100, O0101 and O0102.

As shown in FIG. 8, the finish machining step 44 (steps SC4 and SC9 in FIG. 3) by electric discharge machining in FIG. 2 is a work attachment step 64 in which the rough-machined work W is fixed to, for example, the table 112a of the machine tool 110. It can be disassembled into a processing step 66 and a step 68 of removing from the table 112a. The machining step 66 of FIG. 8 is further decomposed into a step 70 for preparing the electrode E and one or more steps, and in FIG. 9, three steps 72, 74, 76 for executing the machining programs O020, O0201 and O0202. be able to.

In this way, the abstract process plan or basic process stored in the process plan database 20 can be decomposed into a large number of processes for each more specific (less abstract) layer, as shown in FIG. ..

The process decomposition information database 24 stores the decomposed specific processes (tasks) in association with each of the work machines MC1, MC2, MC3, ED1, ED2, UC1 and UC2. By decomposing (subdividing) each process in this way, the content of each process becomes more concrete, and tasks that can be interpreted and executed at the machine level can be obtained. As shown as an example in FIG. 11, the process decomposition information database 24 uses the work machine MC1 as a machine tool capable of performing the process 50 in the process of roughing the mold A by cutting (process 50 in FIG. 7). The jigs and tasks to be used are stored in the form of a combination table in association with each of MC2 and MC3.

For example, based on the schedule received from the schedule calculation unit 12, the process command unit 14 outputs to the process decomposition information providing unit 18 the process of "performing the rough machining of the mold A with the machine tool (working machine) MC1". Based on the received process, the process decomposition information providing unit 18 refers to the process decomposition information database 24, finds jigs, tools, machining programs, and tasks that match the schedule created by the schedule calculation unit 12, and processes the jigs, tools, machining programs, and tasks. Output to the command unit 14.

Even if the machine tool MC1 and the machine tool MC2 can roughen the mold A, the specific tasks and the machining time are different, and the time required for the roughing of the mold A is different. Is different. For example, in the machine tool MC1, as shown in FIG. 12, when the mold A is rough-processed, the door (for example, the door 120b in FIG. 14) is manually opened (end effector 144 of the unmanned transport trolley 140) (process). 80a), the work W (with the end effector 144 of the unmanned transport trolley 140) is attached to the table (for example, 122a in FIG. 14) (step 80b), and the door (for example, the door 120b in FIG. 14) is manually operated (unmanned transport trolley 140). Closed with the end effector 144) (step 80c), cut (step 80d), manually reopened the door (step 80e), and removed the work W (with the end effector 144 of the unmanned carrier 140) from the table. (Step 80f), the door is manually closed again (step 80g), whereas in the machine tool MC2, the door is automatically opened (step 90a) as shown in FIG. 13, (unmanned transport trolley). The work W is attached to the table (with the end effector 144 of 140) (process 90b), the door is automatically closed (process 90c), the cutting process is executed (process 90d), the door is automatically opened again (process 90e), and (process 90e). The work W can be removed from the table (step 90f) (with the end effector 144 of the unmanned transport carriage 140), and the door can be automatically closed again (step 90g). As described above, the specific task for roughing the mold A may be different for each machine tool.

The process command unit 14 has the work machines 30, 32, ... (In FIG. 2, the work machines MC1, MC2, MC3, ED1, ED2) based on the jig, the tool, the machining program, and the task received from the process decomposition information database 24. , UC1, UC2). At that time, by outputting commands to the working machines 30, 32, ... Via the machine control units 26, 28, ..., Each command is in a format conforming to, for example, a protocol of the machine control units 26, 28, ... It can be converted into a command.

For example, an order that includes a known product name, product number or model number, quantity or quantity, and delivery date, such as mold A, is a human-friendly directive or instruction, but abstract for the production system. It cannot be executed as it is. In the present embodiment, a process plan, which is a process model in which the contents of the order are decomposed into one or more specific processes, is set in advance and stored in the process plan database 20 in association with the product name, product number, or model number. , Each process of the process plan is further created as process decomposition information decomposed into one or a plurality of processes, stored in the process decomposition information database 24, and when an order is input, the databases 20 and 24 are referred to. From abstract instructions (orders), it becomes possible to generate more specific tasks that can be interpreted and executed at the machine level.

More specifically, in the present embodiment, the schedule calculation unit 12 creates a schedule based on the input order, and based on the schedule, each process is decomposed into more specific processes to form a production system. Commands are output to the work machines 30, 32, ... (Work machines MC1, MC2, MC3, ED1, ED2, UC1, UC2 in FIG. 2). Since the schedule calculation unit 12 creates a schedule so that a specific process does not significantly rate-determine the production amount or become a bottleneck in the production process, it is possible to improve the production efficiency of the entire production system 100. Further, according to the present embodiment, even if a plurality of products are mixed in one production system, the work machines constituting the production system can be efficiently operated. It is possible to construct a production system suitable for variable-mix production.

In the above-described embodiment, when the schedule calculation unit 12 creates a schedule, the schedule calculation unit 12 sets and stores the schedule calculation unit 12 in the work time database 22 in advance, and each work machine 110-140 of the production system 100 ( Each of the work machines MC1, MC2, MC3, ED1, ED2, UC1, UC2) receives an estimated value (estimated time) of the time required to execute the related steps 38 to 46 from the estimated work time providing unit 16. It has become. However, the present invention is not limited to this, and is required when each of the working machines 110 to 140 (working machines MC1, MC2, MC3, ED1, ED2, UC1, UC2) of the production system 100 executes each step. It is possible to collect the actual time as actual data and store it in the work time database 22. This makes it possible to improve the accuracy of the schedule created by the schedule calculation unit 12. In addition to the time actually required to execute the process, the actual data can be associated with the temperature at the time of executing the process, the tools used, the jig, and the like. Further, the actual data of other factories equipped with the same work machines 110 to 140 (work machines MC1, MC2, MC3, ED1, ED2, UC1, UC2) may be collected and stored via a network such as the Internet. ..

10 Production support system 12 Schedule calculation unit 14 Process command unit 16 Estimated work time providing unit 18 Process disassembly information providing unit 20 Process planning database 22 Working time database 24 Process disassembly information database 100 Production system 100 Machine tool 110 Discharge processing machine 110a Cover 112 Discharge machine body 112a Table 114 Electrode replacement device 116 Machine tool 120 Machine tool 120a Cover 120b Door 122 Cutting machine 122a Table 122b Main shaft 124 Tool changer 130 Machine tool 130a Cover 130b Door 132 Cutting machine 132a Table 132b Main shaft 134 Tool replacement Equipment 136a Iker 136b Iker 138 Work exchange device 138a Door 140 Unmanned transport trolley 142 Robot arm 144 End effector 150 Workstation 152 Feeding workstation 154 Discharging workstation 160 Tool station

Claims (6)

In a production support system that generates a process for producing a product based on an order including information for specifying a product to be produced, a quantity or quantity to be produced, and a due date for completing the production.
Input section for entering orders and
Information on multiple work machines required to produce the product specified by the order based on the order entered from the input unit, the process that each work machine is in charge of, and the time required to execute each process. A schedule calculation unit that generates a schedule including
A process decomposition information providing unit that interprets each process of the generated schedule and decomposes it into multiple tasks, which is information that can be executed by each work machine.
A process command unit that outputs commands to each work machine based on tasks from the process decomposition information provision unit,
A production support system characterized by being equipped with. A process planning database that stores information on multiple work machines required to produce products, the processes that each work machine is in charge of, and the time required to execute each process in association with information that identifies each product. The production support system according to claim 1, further provided. The production support system according to claim 1, further comprising a process decomposition information database in which a process stored in a process planning database and a process decomposition information database in which tasks are stored in association with each work machine that executes the process are provided. The production support system according to claim 1, further comprising a work time database in which information on the time required for a work machine to execute a process included in a schedule is stored in association with the process and the work machine. The production support system according to claim 4, wherein the actual time required for the work machine to execute the process included in the schedule is stored in the work time database. The production support system according to claim 1, wherein the work machine includes a plurality of machine tools and an automatic guided vehicle that transports the work between the machine tools.

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